三一电气精益生产

三一电气精益生产摘要培训材料LEVEL1:精益简要,排除浪费2培训注意事项尊重自己、尊重其他学员，保持手机静默或关机;优秀的人才从守时开始(迟到一分钟罚款5元)培训前请签到，请假需提前1天报告培训结束后做好您方圆0.5M的5S对自己的成长负责，积极发问；空杯心态，获得更多；Agenda议程TheHistoryofLean--ToyotaProductionSystem精益的历史与丰田生产系统LeanDefinition&7Wastes精益的定义及7种浪费LeanPhysicalTransformation精益的实体变革LeanManagementSystem精益管理系统Exercise:Bytable/groupcomeupwithyourdefinitionof揕ean练习：按课桌/小组给出您对“精益”的定义WhatisLean?什么是精益？Lean精益leanadj.精益：形容词1a:lackingordeficientinflesh.b:containinglittleornofata:无肉或少肉b:少脂肪或无脂肪2:lackingrichness不富裕3:deficientinanessentialorimportantqualityoringredient在必要性、重要性、质量或成分方面稀缺4:charac-terizedbyeconomyofstyleorexpression文体或措辞简练syn.thin,skinny,lanky,scrawny,gaunt,bony,emaciated,svelte,lank同义词：薄、极瘦、过分瘦长、骨瘦如柴、瘦削的、似骨的、消瘦的、细长的、瘦长的ant.fat,fleshy,overweight,flabby,obese,plump,chunky,corpulent,soft反义词：肥胖的、多肉的、过重的、不结实的、过分肥胖的、丰满的、粗短的、肥大的、软的WhatisLean?-Womack什么是精益1.Definevaluepreciselyfromtheperspectiveoftheendcustomer从最终用户的角度准确地定义价值2.Identifytheentirevaluestreamforeachproductorproductfamilyandeliminatewaste确定每一种产品或产品系列的整个价值流，消除浪费3.Maketheremainingvaluecreatingstepsflow理顺创造价值的步骤4.Designandprovidewhatthecustomerwantsonlywhenthecustomerwantsit只在客户需要时设计和提供他们所需的东西5.Pursueperfection追求完美WHATARETHEOBJECTIVESOFLEAN?精益的目的Quality质量Cost成本On-timeDelivery及时交货建立消除浪费的文化为我们的客户提供价值的最大化目的-客户&股东8CustomerExpectations客户期望PerformsAsExpected按预期执行WorkswhenNeeded当需要时,既可用CostasLittleasPossible尽可能低的成本Don’twanttoWait不想等待“EstablishingaCultureofRelentlessWasteEliminationtoDeliverCustomerValue”ShareholderExpectations股东期望UseMinimumAssets尽可能少的资产MaximizeReturnonInvestment投资回报率最大化Agenda议程TheHistoryofLean--ToyotaProductionSystem精益的历史与丰田生产系统LeanDefinition&7Wastes精益的定义及7种浪费LeanPhysicalTransformation精益的实体变革LeanManagementSystem精益管理系统HistoryofLean历史新郎重夫大野惠特丽吉尔布雷思泰勒.工业工程之父ToyotaProductionSystemProductionSmoothingJustInTimeJidoka通过减少成本消除浪费HowdoweDefineValue如何定义价值12ValueAddActivity价值增值的活动TransformingofRawMaterialsandInformationIntoPartsorProductsinaWaytheCustomerValues(WillingtoPayFor)任何将信息和原材料转化为零件或产品,且客户愿意支付的活动Examples:Milling,Boring,Drilling,Punching,Others?例如:洗削,钻孔,冲压Non-ValueAddActivity非价值增值的活动ElementsoftheProcessThatAddTime,Effort,Cost,butNoValueAlsoCalledWaste任何付出时间,努力,成本,但没有价值的活动,也叫浪费WasteAreSymptomsofaProblem,NotRootCauses浪费是问题的表像,非根本原因WasteIdentification浪费辨识Operation加工Seconds秒(Processing/Work)Transportation运输Minutes分Inspection检验Sec/Min秒/分Searching寻找Minutes/Hours(ToolsandMaterials)分/小时Storage储存Hours/Days/Months(Waiting/Stops)小时/天/月TimeConsumed时间WhatCustomerPaysFor客户支付PRODUCTION生产YESNONONONOValueAdd-vs-Non-ValueAdd价值增值及非增值14TypicalCompany典型企业TraditionalManufacturingImprovement传统制造改善LeanWasteReduction精益的浪费减少OriginalLeadTime最初的提前期MajorImprovement较大的改善NVA非增值NVA非增值NVA非增值VA增值VA增值VA增值MinorImprovement较少的改善Time时间ProductLeadTime提前期1%to5%15TheHistoryofLean--ToyotaProductionSystem精益的历史与丰田生产系统LeanDefinition&7Wastes精益的定义及7种浪费LeanPhysicalTransformation精益的实体变革LeanManagementSystem精益管理系统7Wastes7种浪费1617!!!返工库存堆积寻找工具?FactorySituation工厂的情景…FactorySituation工厂内的情景..仓库临时库房??清点部件数量将库存数据人工输入电脑观看机器运转部件远距离运输WasteofOverproduction过度生产的浪费19Definition:•ProducingMoreThanNeeded•ProducingFasterThanNeeded定义:•生产超过了需求•生产快过了需求WasteofOverproduction过度生产的浪费20Characteristics特点:•InventoryStockpiles库存积压•ExtraEquipment额外的设备•ExtraStorageRacks额外的仓储架•ExtraManpower额外的人力•AdditionalFloorSpace更多的工作场地Causes原因:•IncapableProcesses过程能力低下•LackofCommunication缺乏交流•LongToolChanges工具更换周期长•LackoflevelSchedules缺乏均衡生产•Misuseofautomation自动化的滥用•Lowuptimes劳动工时利用率低21Definition:AnymovementofmaterialthatisnotrequiredforJITproduction.WasteofMaterialTransportation材料移动/传送的浪费定义:任何不是为了即时需要的物料移动。22Characteristics特点:•ExtraForkTrucks额外的叉车•MultipleStorageLocations多处储存地点•ExtraFacilitySpace额外的设施空间•Largelots大批量•Lackofpullsystem缺乏拉动系统Causes原因:•UnleveledSchedules计划安排不平衡•LongChangeOverTimes更换品种时间长•LackofWorkPlaceOrganization工作场地缺乏组织•ImproperFacilityLayout设备布局不当•LargerBufferandBanks缓冲库存区过大•Lackofaddresssystem缺乏地址系统WasteofMaterialTransportation材料移动/传送的浪费WasteofMotion动作的浪费23Definition定义:Anymovementofpeopleormachineswhichdoesnotcontributevaluetotheproductorservice.任何对生产和服务没有带来价值的人员或机器的运动。WasteofMotion动作的浪费24Characteristics特点:•LookingforTools寻找工具•ExcessiveReaching/Bending过度伸展/弯腰•Machines/MaterialTooFarApart(WalkTime)机器/材料距离过远（步行的时间)•Clutterworkarea工作区域混乱不堪Causes原因:•Equipment,Office&PlantLayout设备、办公室和工厂的布局不当•LackofWorkPlaceOrganization工作场地缺乏组织•PoorPerson/MachineEffectiveness人员/机器效率不高•PoorErgonomicDesign人机工程方面的设计不好•InconsistentWorkMethods不一致的工作方法•LargeBatchSizes加工批量过大WasteofWaiting等待的浪费25Definition:Beingidlebetweentwooperation.定义:在两个操作之间无事可做。WasteofWaiting等待的浪费26Characteristics特点:•PersonWaitingforMachine人员等候机器•MachineWaitingforthePerson机器等候人员•OnePersonWaitingforAnotherPerson一个人等候另一个人•UnbalancedOperations(Work)不平衡的操作（工作）•UnplannedEquipmentDowntime计划外停机Causes原因:•InconsistentWorkMethods不一致的工作方法•LongMachineChangeOverTimes机器设置时间长•PoorMan/MachineEffectiveness人员/机器总体效率不高•LackofProperMachines缺乏合适的机器•LackofEquipmentResources缺乏设备资源WasteofInventory库存的浪费27Definition:Anysupplyinexcessofprocessrequirementsnecessarytoproducegoods.定义:任何超过生产产品过程所需要的供应。W